Live CHAT

LOOK HERE

JOIN

TurboClub

 NOW FREE

 NEW MEMBERS WEBSITE HERE

Many Makes - Models

TurboClub.com MEMBERS Website now online FREE!

REGISTER NOW

1982 Australia Starion 2.0 Ltr - 4G63BT Engine Specifications

GENERAL

No. and arrangement of cylinders.....................................4, in-line, vertical

Combustion chamber type................................................ Hemi-spherical

Valve arrangement...............................................................Overhead valve type

Camshaft arrangement........................................................Single Overhead Camshaft

Total displacement cc (cu.in.)............................................1 997 (121.8)

Bore x Stroke mm (in.).........................................................85 x 88 (3.35 x 3.46)

Compression ratio...............................................................7.6

Compression press. kPa (kg/c M2, psi)...........................834 (8.5, 12 1) or more at 250 rpm.

Valve timing Inlet valve opened/closed..........................BTDC 2 1 '/ABDC 63'

Exhaust valve opened/closed...........................................BBDC 63o/ATDC 2 1

Firing order..........................................................................1 - 3 - 4 - 2

Valve clearance at hot engine mm (in.).

Exhaust.................................................................................0.15 (0.006)...

Inlet...................................................................................... 0.25 (0.010)

Exhaust Ignition timing at idling speed...........................BTDC 8' @ 2'

Idling speed rpm.................................................................800 50

CO concentration at idling................................................2.5 0.5%

TIMING BELT

Type.......................................Cogged type

No. of teeth..........................122

Width mm (in.).....................19 (0.75)

TIMING BELT "B" for SILENT SHAFT DRIVE

Type.......................................Coggedtype

No. of teeth..........................55

Width mm (in.).....................12.7 (0.5)

CRANKSHAFT SPROCKET

Material.................................Ferrous sintered alloy

No. of teeth..........................24

CRANKSHAFT SPROCKET "B"

Material................................Ferrous sintered alloy

No. of teeth..........................32

CAMSHAFT SPROCKET

Material................................Cast iron

No. of teeth..........................48

OIL PUMP SPROCKET

Material................................Ferrous sintered alloy

No. of teeth..........................18

SILENT SHAFT SPROCKET

Material.................................Ferrous sintered alloy

No. of teeth..........................16

ROCKER ARM

Material..............................Aluminium die casting

CAMSHAFT

Driven by.........................................................Cogged type belt

Material............................................................Cast iron, Cam surface chilled

Cam height mm (in.)........................................42.2 (1.661)

Valve lift mm (in.)............................................10 (0.394)

Cam diameter for fuel pump drive mm(in.)....38 (1.496)

Journal diameter mm (in.).................................34 (1.339)

Oil clearance mm (in.).......................................0.05 - 0.09 (0.002 - 0.004)

Identification mark............................................2

CYLINDER HEAD

Material.............................................................Aluminium alloy

Flatness of gasket surface mm (in.)..............Max. 0.1 (0.004)

Valve guide hole diameter mm (in.)

0.05 (0.002) O.S......13.050 - 13.068 (0.5138 - 0.5145)

0.25 (0.01 0) O-S......13.250 - 13.268 (0.5217 - 0.5224)

0.50 (0.020) O.S......13.500 - 13-518 (0-5315 - 0.5322)

Inlet valve seat ring hole diameter mm (in.)

0.3 (0.012) O.S......44.300 - 44.325 (1.7441 - 1.7451)

0.6 (0.024) O.S......44.600 - 44.625 (1.7559 - 1.7569)

Exhaust valve seat ring hole diameter mm(in.)

0.3 (0.012) O.S......38.300 - 38.325 (1-5079 - 1.5089)

0.6 (0.024) O.S......38.600 - 38.625 (1.5197 - 1.5206)

Valve guide installing height mm (in.)............15 (0.591)

INLET VALVE

Material...................................................Special heat resisting steel

Treatment................................................Tufftriding

Valve diameter mm (in.)..........................43 (1.693)

Stem diameter mm (in.)............................8.0 (0.3150)

Clearance (Stem-to-guide) mm (in.).......0.03 - 0.06 (0.0012 - 0.0024)

Margin mm (in.)........................................1.2 (0,047)

Identification mark....................................6

EXHAUST VALVE

Material............................................................Special heat resisting steel, Valve face padded with stellite

Treatment........................................................Tufftriding

Valve diameter mm (in.).................................35 (1.378)

Stem diameter mm (in.)..................................8.0 (0.3150)

Clearance (Stem-to-guide) mm (in.).............0.05 - 0.09 (0.0020 - 0.0035)

Margin mm (in.)..............................................2.0 (0.079)

Identification mark.........................................5S

VALVE SPRING

Free height mm (in.)........................................47.5 (1.870)

Load N (kg,lbs.)/mm(in.).................................275 (28,62)/40.4 (1-591)

Square...............................................................Less than 1.5'

Identification color..........................................Blue

Bottom End

RIGHT SILENT SHAFT

Driven by.................................................Cogged type belt

Material....................................................Steel

Front journal diameter mm (in.).............42 (1-654)

Rear journal diameter mm (in.)...............41 (1.614)

Oil clearance mm (in.)

Front............................0.02 - 0.06 (0.0008 - 0.0024)

Rear.............................0.05 - 0.09 (0.0020 - 0.0035)

LEFT SILENT SHAFT

Driven by...................................................Cogged type belt

Material.......................................................Steel

Front journal diameter mm (in.)...............18.5 (0.728)

Rear journal diameter mm (in.).................41 (1.614)

Oil clearance mm (in.)

Front............................0.02 - 0.05 (0.0008 - 0.0020)

Rear.............................0.05 - 0.09 (0.0020 - 0.0035)

PISTON

Material.............................................................Special aluminium alloy

Type...................................................................Autothermic (Steel strut incorporated)

Diameter (Standard) mm (in.)..........................85.0 (3.346)

Clearance (Piston-to-cylinder) mm (in.).........0.03 - 0.05 (0.0012 - 0.0020)-

Identification mark............................................63T

Pistons for service mm (in.).............................0.25 (0.010),O.50 (0-020) 0.75 (0.030),1.00 (0.040), oversize

PISTON RING

No. of rings per piston............3

Compression.............................2

Oil...............................................1

Compression ring type

No. 1..........................................Barrel type, special cast iron, chrome face

No. 2...........................................Taper type, special cast iron, chrome face

Oil ring type..............................3-piece type, steel rail chrome face

Ring gap mm (in.)

No. 1................0.25 - 0.40 (0.010 - 0.016)

No. 2................0.2 - 0.4 (0.008 - 0.016)

Oil....................0.2 - 0.7 (0-008 - 0.028)

Ring side clearance mm (in.)

No. 1..............0.05 - 0.09 (0.002 - 0.004)

No. 2.............0.02 - 0.06 (0.001 - 0.002)

Identification mark No. 1 and No. 2...........NN

Oil.......................Green paint

Rings for service mm (in.)..0.25 (0.010),O.50 (0.020), 0.75 (0.030),1.00 (0.040), oversize

CONNECTING ROD

Length (Center to center) mm (in.).....150 (5.906)

CRANKSHAFT

Material..................................Steel Treatment.................................Gas-carbonitriding

Main bearing journal diameter mm (in.).....................................................57 (2.244)

Connecting rod journal diameter mm (in.).................................................45 (1.772)

Maximum allowable out-of-round and/or taper of journal mm (in.)........0.01 (0.0004)

Oil clearance mm (in.) Main bearing journal...............................................0.02 - 0.05 (0.0008 - 0.0020)

Connecting rod journal..................................................................................0.02 - 0.05 (0.0008 - 0.0020)

Thrust taken by...........................No. 3 main bearing

End play mm (in.).........................0.05 - 0.18 (0.0020 - 0.0071)

Bearings for service available in standard size

and following undersize mm (in.).....0.25 (0.010),O.50 (0.020),O.75 (0.030)

CYLINDER BLOCK

Material...............................................................................................Cast iron

Water jacket........................................................................................Siamese type

Cylinder bore mm (in.)........................................................................85.0 (3.346)

Out-of-round and taper mm (in.).......................................................Less than 0.02 (0.0008)

Maximum allowable oversize (Cylinder bore) mm (in.) ..................1.00 (0.039)

OIL PUMP

Type.........................................Gear Driven by....................................Cogged type belt

Oil pressure at idle kPa (kg/cM2.psi)................................................78 (0.8, 1 1) or more

OIL FILTER

Type....................................................................................Cartridge, Full flow .

Size (Diameter x Length) mm (in.)...................................90 x 100 (3.54 x 3.94)

Relief valve opening pressure kPa (kg/cm2, psi)..........98 (1.0,14)

OIL FILTER BRACKET

Oil relief valve opening pressure kPa (kg/cm2, psi)..........................539 (5.5,78)

Oil cooler by-pass valve By-pass hole closing temperature............1 OO'C (21 2'F)

Oil cooler by-pass pressure kPa (kg/cM2, psi)...................................147 (1.5, 21)

ENGINE OIL

Capacity including that of oil filter lit. (U.S.qts., Imp.qts.)...............4.0 (4.2, 3.5) without oil cooler

Recommended oil (API classification).................................................SE or higher

ECI- TURBO SYSTEM

TURBOCHARGER

Type.............................................................Exhaust gas turbine type

Model No....................................................TC06-11 A-8

Supercharging pressure control.............Waste gate valve

Waste gate actuater operating pressure

INJECTION MIXER

Part No. / Model No...............................MD041776 / 50EID-701.... EC

Injector Type...................................................Electromagnetic type

No. of injectors................................................2

Nozzle diameter mm (in.).................................1.25 (0.049)

Coil resistance..................................................2.5 ohm

Fuel pressure regulator

Regulated pressure kPa (kg/cM2, psi).........245 (2.5, 35.6)

Throttle sensor Type.....................................Variable resistor type

Resistance.......................................................4 - 6kil

Idle switch (Idle speed adjusting screw)

Type......................................Contact point type Variable resistor (Idle mixture adjustment)

Type......................................Variable resistor type Idle up solenoid for A/C

Type......................................Electromagnetic type.. with A/C only

Dash pot Type....................CVtype..... AUS

COMPUTER

Part No. / Model No..................MD041932 E2T30371....LHD

AIR CLEANER

Type.......................................Unwoven cloth type with air flow sensor

Identification No..................MD041953

AIR FLOW SENSOR

Type......................................Karman vortex type with intake air temp. sensor

Part No. / Model No............MD607697 / E005TOO271

INTAKE AIR TEMPERATURE SENSOR

Type...............................................................Thermister

Resistance.....................................................2.2 k ohm at 25'C (77'F)

RESISTOR

Model No.......................................................E8TOO271

Resistance......................................................6 ohm

WATER TEMPERATURE SENSOR

Type................................................................Thermistor

Resistance.....................16,200 ohm at -20'C (-4'F) 2,450 ohm at 20'C (68'F) 296 ohm at 80'C (176'F)

CONTROL RELAY

FUEL PUMP

Type..................................................Motor-driven roller vane type

Relief valve op. press. kPa (kg/cM2, psi)....441 - 588 (4.5 - 6, 64 - 85) at zero discharge flow

Discharge flow at room temperature (reference) lit. (cu.in.)..............................90 - 120 (5.5 - 7.3)

at 12 volt, 245 - 324 kPa (2.5 - 3.3 kg/cM2, 35 - 47 psi)

Identification No............................MD018360...... A164A MD041735....... A183A

DISTRIBUTOR

Part No. / Model No......................MD001633/T4T62373

Type................................................Breaker-pointless type

Ignition timing advance Governor [Crank angle at engine speed rpm].. O'/l 000 - 22'/2 400 - 26'/3 500

Vacuum [Crank angle at pressure kPa (mmHg, in.Hg) O'/ - 1 0.7 (- 80, - 3.1) - 1 9'/ - 49.3 370, - 14.6)

Ignition timing retard [Crank angle at pressure kPa (mmHg, in.Hg)].... O'/l 3.3 (100, 3.9) - 14'/40 (300, 1 1.8)

IGNITER

Part No. / Model No.....................MD001635/E2Tl5l7l

KNOCK SENSOR

Type...............................................Piezo-electric element

Part No. / Model No.....................MD001637/E2Tl5671

IGNITION COIL

Type...............................................Oil filled type

Model No.......................................LB-1 19

Primary coil resistance.................1. 1 5 fl at 20'C (680F)

Secondary coil resistance............8.35 kfl at 2OoC (68'F)

SPARKPLUG

Model No............................BR7ES (NGK) or W22ESR-U...EC B7ES.......... AUS

COOLING SYSTEM

Cooling method..................Water cooling, forced circulation

WATER PUMP

Type............................Centrifugal impeller

Driven by...................V" type belt

COOLING FAN

Type............................Electric fan...See Chassis group Workshop Manual

DRIVE BELT

Type............................Low-edge plain "HM" Length mm (in.)................972 (38.28)

THERMOSTAT

Type............................Wax type with jiggle valve

Valve opening temperature.......88'C (190'F).. A164A 82'C (1 80'F)....A183A

ELECTRICAL SYSTEM

STARTER MOTOR -

DIRECT DRIVE TYPE...........except ECC

Part No. / Model No........................MD027400 / M3T25782

Voltage..............................................12V

Output...............................................0.9 kW

No. of fields.....................................4

No. of poles.....................................4

No. of brushes.................................3

Drive..................................................Solenoid shift overrunning clutch

No-load test Voltage.......................1 1.5v

Amperage draw...............................60A

Minimum speed rpm.......................6 500

Pinion gap mm (in.).........................0.5 - 2.0 (0.020 - 0.079)

STARTER MOTOR

- REDUCTION DRIVE TYPE.......for ECC only

Part No. / Model No........................MD027382 / M2T53083

Voltage..............................................12V

Output...............................................1.2 kW

No. of fields......................................4

No. of poles......................................4

No. of brushes.................................4

Drive..................................................Solenoid shift overrunning clutch

Reduction.........................................3.6: 1

No-load test Voltage......................1 1.5v

Amperage draw...............................1 OOA

Minimum speed rpm.......................3 000

Pinion gap mm (in.).........................0.5 - 2.0 (0.020 - 0.079)

IGNITION SYSTEM......................See "ECI-TURBO SYSTEM"

ALTERNATOR

Part No. Model No..........................MD041706 / A3T32872

Voltage................................................................................12V

Amperage (Nominal)..........................................................65A

Rotation................................................................................Clockwise

Regulated voltage at 200C (680F).....................................14.1 - 14.7V

Temperature compensation gradiant at 1 OIC (1 8'F)..... - O.lV

Voltage regulator...................................................................Electronic type

CLUTCH

CLUTCH

Control method......................................Hydraulic control type

CLUTCH DISC

Type........................................................Dry, single plate

Facing size O.D. x I.D. mm (in.)...........225 x 150 (8-86 x 5.91)

CLUTCH COVER ASSEMBLY

Type........................................................Diaphragm spring type

Setting load N (kg. lbs.)........................5 400 (550.1 213)

RELEASE BEARING

Type.........................................................Self-centering type

Free travel mm (in.).................................Zero (Constant contact type)

MANUAL TRANSMISSION - KM 132

GENERAL

Type............................................5-speed. Floor-shift